Super absorbent polymer and preparation method thereof

ABSTRACT

The present invention relates to a super absorbent polymer and a preparation method thereof, the super absorbent polymer including: surface cross-linked polymer particles prepared by surface cross-linking particles of a base resin, the base resin polymerized from a monomer composition including water-soluble ethylene-based unsaturated monomers having at least partially neutralized acidic groups; and a water-soluble component, wherein the water-soluble component has a weight average molecular weight of 150,000 to 300,000 g/mol. The super absorbent polymer may have high centrifuge retention capacity and excellent permeability at the same time, while having low content of the water-soluble component.

CROSS-REFERENCE TO RELATED APPLICATIONS

The application claims priority and the benefit of Korean PatentApplication No. 10-2013-0053935 filed in the Korean IntellectualProperty Office on May 13, 2013 and Korean Patent Application No.10-2014-0051816 filed in the Korean Intellectual Property Office on Apr.29, 2014, as well as PCT application No. PCT/KR2014/003821 on Apr. 30,2014 with the WIPO, the entire content of which is incorporated hereinby reference.

BACKGROUND OF THE INVENTION

(a) Field of the Invention

The present invention relates to a super absorbent polymer and apreparation method thereof.

(b) Description of the Related Art

A super absorbent polymer (SAP) is a synthetic polymeric materialcapable of absorbing water five hundred up to one thousand times themass of its own. The SAP is called by different names according to thedevelopers, for example, a super absorbency material (SAM), an absorbentgel material (AGM), and the like. Commercial productions of the SAPbegan for use in feminine hygiene napkins, nowadays, the use of SAP maybe found in a very wide range of applications, including watercombination soils for gardening, water-stop materials for engineeringand construction, sheets for raising seeding, freshness-keeping agentsin the food distribution field, and materials for sweating rooms, aswell as personal hygiene products, such as disposable baby diapers.

Known preparation methods for SAP include an inverse suspensionpolymerization method or an aqueous solution polymerization method. Themethod using inverse suspension polymerization is disclosed in, forexample, JP S-56-161408, JP S-57-158209 and JP S-57-198714. The methodusing aqueous solution polymerization includes several methods: athermal polymerization method including polymerization of a hydrogelpolymer by shearing and freezing in a kneading machine provided withseveral spindles, and a photopolymerization method using UV radiationson a high-concentration aqueous solution on a conveyer belt to performboth polymerization and drying at once.

Meanwhile, a water-soluble component, that is, a polymer which is notcross-linked in the preparation method of the super absorbent polymer,is produced. When the water-soluble component has a high content, asolution absorption capacity of the super absorbent polymer is improved;meanwhile, when the super absorbent polymer contacts a liquid, the superabsorbent polymer is easily eluted to make a surface sticky or to have anegative effect on a skin to be contacted. In addition, when thewater-soluble component has a high content, the eluted water-solublecomponent generally remains on the surface of the super absorbentpolymer to make the super absorbent polymer sticky, such thatpermeability which is a capacity of rapidly delivering a solution toother super absorbent polymers is decreased.

Therefore, development of a super absorbent polymer having highabsorbency and excellent permeability has been demanded.

SUMMARY OF THE INVENTION

The present invention has been made in an effort to provide a superabsorbent polymer having high centrifuge retention capacity andexcellent permeability at the same time.

An exemplary embodiment of the present invention provides a superabsorbent polymer including: surface cross-linked polymer particlesprepared by surface cross-linking particles of a base resin, the baseresin polymerizing from a monomer composition including water-solubleethylene-based unsaturated monomers having at least partiallyneutralized acidic groups; and a water-soluble component, wherein thewater-soluble component has a weight average molecular weight of 150,000to 300,000 g/mol.

In the super absorbent polymer, the water-soluble component measured bythe EDANA WSP 270.2 method may have a content of 5 to 20 wt % based onthe total weight of the super absorbent polymer.

In the super absorbent polymer, a centrifuge retention capacity measuredby the EDANA WSP 241.2 method may be 20 to 35 g/g.

In the super absorbent polymer, an absorbency under load measured by theEDANA WSP 242.2 method may be 20 to 30 g/g.

In the super absorbent polymer, a permeability measured according to thefollowing Equation 1 may be 10 to 150 seconds:

Permeability (sec)=T1−B  [Equation 1]

T1 represents a time required for decreasing a liquid level height from40 ml up to 20 ml under a load of 0.3 psi (106.26 g) in a chromatographytube in the presence of saline solution-absorbed super absorbentpolymer, wherein the saline solution-absorbed super absorbed polymer isprepared by putting 0.2±0.0005 g of a classified sample (30# to 50#)(particles size ranging from 300 μm to 600 μm) of super absorbentpolymer into the chromatography tube and adding saline solution so thatthe saline solution has a volume of 50 ml, and leaving the tube for 30minutes prior to measuring T1, and

B represents a time required for decreasing a liquid level height from40 ml up to 20 ml in a chromatography tube filled with saline solutionunder a load of 0.3 psi in the absence of the super absorbent polymer.

Another exemplary embodiment of the present invention provides apreparation method of a super absorbent polymer, including: preparing amonomer composition including a water-soluble ethylene-based unsaturatedmonomers have un-neutralized acidic groups, and a polymerizationinitiator, wherein the polymerization initiator has a content of 40 to300 ppm based on the amount of water-soluble ethylene-based unsaturatedmonomers; adding a neutralizing agent to the monomer composition toneutralize at least some of the un-neutralized acidic groups of thewater-soluble ethylene-based unsaturated monomers; preparing a hydrogelpolymer by polymerizing the monomer composition, wherein apolymerization temperature ranges from 20 to 45° C.; drying the hydrogelpolymer; pulverizing the dried polymer to form particles; and surfacecross-linking the particles in the presence of a surface cross-linkingagent to form surface cross-linked polymer particles of the superabsorbent polymer, wherein the surface cross-linking agent is present inan amount ranging from 0.15 to 0.7 wt % based on an amount of theparticles.

A water-soluble component included in the super absorbent polymer mayhave a weight average molecular weight of 150,000 to 300,000 g/mol.

The super absorbent polymer according to the present invention may havehigh centrifuge retention capacity and excellent permeability at thesame time, while having low content of the water-soluble component.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Although the present invention can be modified variously and haveseveral embodiments, the exemplary embodiments are illustrated in theaccompanying drawings and will be described in detail in the detaileddescription. However, the present invention is not limited to thespecific embodiments and should be construed as including all thechanges, equivalents, and substitutions included in the spirit and scopeof the present invention. Further, when it is determined that thedetailed description of the known art related to the present inventionmay obscure the gist of the present invention, the detailed descriptionthereof will be omitted.

The present invention provides a super absorbent polymer including:surface cross-linked polymer particles prepared by surface cross-linkingparticles of a base resin, the base resin polymerizing from a monomercomposition including water-soluble ethylene-based unsaturated monomershaving at least partially neutralized acidic groups; and a water-solublecomponent, wherein the water-soluble component has a weight averagemolecular weight of 150,000 to 300,000 g/mol.

In addition, the present invention provides a preparation method of asuper absorbent polymer, including: preparing a monomer compositionincluding a water-soluble ethylene-based unsaturated monomers haveun-neutralized acidic groups, and a polymerization initiator, whereinthe polymerization initiator has a content of 40 to 300 ppm based on theamount of water-soluble ethylene-based unsaturated monomers; adding aneutralizing agent to the monomer composition to neutralize at leastsome of the un-neutralized acidic groups of the water-solubleethylene-based unsaturated monomers; preparing a hydrogel polymer bypolymerizing the monomer composition, wherein a polymerizationtemperature ranges from 20 to 45° C.; drying the hydrogel polymer;pulverizing the dried polymer to form particles; and surfacecross-linking the particles in the presence of a surface cross-linkingagent to form surface cross-linked polymer particles of the superabsorbent polymer, wherein the surface cross-linking agent is present inan amount ranging from 0.15 to 0.7 wt % based on an amount of theparticles.

Hereinafter, a super absorbent polymer according to an exemplaryembodiment of the present invention and a preparation method of thesuper absorbent polymer are described in more detail.

According to an exemplary embodiment of the present invention, there isprovided a super absorbent polymer including: surface cross-linkedpolymer particles prepared by surface cross-linking particles of a baseresin, the base resin polymerizing from a monomer composition includingwater-soluble ethylene-based unsaturated monomers having at leastpartially neutralized acidic groups; and a water-soluble component,wherein the water-soluble component has a weight average molecularweight of 150,000 to 300,000 g/mol.

The water-soluble component generally has various molecular weightdistributions, and in the present invention, a molecular weight of thewater-soluble component indicates a weight average molecular weightthereof.

The water-soluble component, that is, a polymer which is notcross-linked in the preparation method of the super absorbent polymer,is produced. When the water-soluble component has a high content, anabsorption capacity of the super absorbent polymer is improved;meanwhile, when contacting a liquid, the super absorbent polymer iseasily eluted to make a surface of a diaper, and the like, sticky or todamage a skin, and the like. Meanwhile, when the water-soluble componenthas a high content, the eluted water-soluble component generally remainson the surface of the super absorbent polymer to make the superabsorbent polymer sticky, such that permeability is decreased. Theabsorbency and permeability are opposite properties, and the superabsorbent polymer having both of improved absorbency and permeabilitymay exhibit significantly excellent physical properties. In particular,for example, when considering recent trend that the diaper has a slimthickness, these properties become significantly important.

Meanwhile, during the polymerization, cross-linkage of the water-solublecomponent of the super absorbent polymer is not complete, such that thewater-soluble component may be present in a state that the water-solublecomponent is not cross-linked. However, the water-soluble component maybe generally generated by decomposition of a cross-linking agent orbreak of a main polymer chain in a drying process. In this case, adanling chain of which one side is cross-linked but the other side isnot cross-linked to have a free polymer chain form, rather than thecross-linked chain, is eluted as the water-soluble component, when thepolymer chain is decomposed by heat.

The present invention provides the super absorbent polymer in which thewater-soluble component has a weight average molecular weight of 150,000to 300,000 g/mol, or 150,000 to 250,000 g/mol, or 180,000 to 250,000g/mol, or 200,000 to 250,000 g/mol, in order to provide the superabsorbent polymer having high centrifuge retention capacity andexcellent permeability while including a low content of thewater-soluble component, considering that a molecular weightdistribution of the eluted water-soluble component as well as thecontent of the water-soluble component have an effect on absorbency andpermeability.

In the super absorbent polymer, the water-soluble component measured bythe EDANA WSP 270.2 method may have a content of 5 to 20 wt %, or 5 to15 wt %, or 5 to 12 wt %, or 9 to 12 wt % based on the total weight ofthe super absorbent polymer.

In addition, in the super absorbent polymer, the centrifuge retentioncapacity measured by the EDANA WSP 241.2 method may be 20 to 35 g/g, or25 to 35 g/g, or 30 to 35 g/g.

Further, in the super absorbent polymer, the absorbency under loadmeasured by the EDANA WSP 242.2 method may be 20 to 30 g/g, or 20 to 28g/g, or 22 to 26 g/g.

In addition, in the super absorbent polymer, the permeability (sec)measured according to the following Equation 1 may be 10 to 150 seconds,or 20 to 120 seconds, or 50 to 120 seconds, or 80 to 120 seconds.

Permeability (sec)=T1−B  [Equation 1]

T1 represents a time required for decreasing a liquid level height from40 ml up to 20 ml under a load of 0.3 psi (106.26 g) in a chromatographytube in the presence of saline solution-absorbed super absorbentpolymer, wherein the saline solution-absorbed super absorbed polymer isprepared by putting 0.2±0.0005 g of a classified sample (30# to 50#)(particles size ranging from 300 μm to 600 μm) of super absorbentpolymer into the chromatography tube and adding saline solution so thatthe saline solution has a volume of 50 ml, and leaving the tube for 30minutes prior to measuring T1, and

B represents a time required for decreasing a liquid level height from40 ml up to 20 ml in a chromatography tube filled with saline solutionunder a load of 0.3 psi in the absence of the super absorbent polymer.

According to an exemplary embodiment of the present invention, thepresent invention provides a preparation method of a super absorbentpolymer, including: preparing a monomer composition including awater-soluble ethylene-based unsaturated monomers have un-neutralizedacidic groups, and a polymerization initiator, wherein thepolymerization initiator has a content of 40 to 300 ppm based on theamount of water-soluble ethylene-based unsaturated monomers; adding aneutralizing agent to the monomer composition to neutralize at leastsome of the un-neutralized acidic groups of the water-solubleethylene-based unsaturated monomers; preparing a hydrogel polymer bypolymerizing the monomer composition, wherein a polymerizationtemperature ranges from 20 to 45° C.; drying the hydrogel polymer;pulverizing the dried polymer to form particles; and surfacecross-linking the particles in the presence of a surface cross-linkingagent to form surface cross-linked polymer particles of the superabsorbent polymer, wherein the surface cross-linking agent is present inan amount ranging from 0.15 to 0.7 wt % based on an amount of theparticles.

The water-soluble component included in the super absorbent polymerprepared according to the preparation method as described above may havea weight average molecular weight of 150,000 to 300,000 g/mol, or150,000 to 250,000 g/mol, or 180,000 to 250,000 g/mol or 200,000 to250,000 g/mol.

In addition, in the super absorbent polymer prepared according to thepreparation method as described above, the water-soluble componentmeasured by the EDANA WSP 270.2 method may have a content of 5 to 20 wt%, or 5 to 15 wt %, or 5 to 12 wt %, or 9 to 12 wt % based on the totalweight of the super absorbent polymer.

The water-soluble component has a large difference in an overall contentof the water-soluble component and a molecular weight of thewater-soluble component depending on a content of an initiator to beused at the time of polymerization, a polymerization temperature, and acontent of a cross-linking agent, and as the content of the initiatorbecomes decreased, and the polymerization temperature becomes decreased,and the content of the cross-linking agent becomes increased, it isgeneral to decrease the molecular weight of the water-soluble component.

Meanwhile, since the molecular weight and the content of thewater-soluble component are related with various process conditions asdescribed above, it is not easy to obtain optimized molecular weight andcontent of the water-soluble component by controlling various variables.However, according to the preparation method of the present invention,the present inventors found the weight average molecular weight andcontent ranges of the water-soluble component balancing the centrifugeretention capacity and the permeability by controlling the content ofthe polymerization initiator, and the polymerization temperature at thetime of preparing the hydrogel polymer, and the content of the surfacecross-linking agent at the time of performing surface cross-linking onthe polymer within optimized ranges, respectively, and therefore, thesuper absorbent polymer having high centrifuge retention capacity andexcellent permeability at the same time could be obtained, thencompleted the present invention.

According to an exemplary embodiment of the present invention, a monomercomposition including a water-soluble ethylene-based unsaturatedmonomers and a polymerization initiator is prepared, and a hydrogelpolymer is prepared by polymerizing the monomer composition.

In the above-description, in the polymerizing of the monomercomposition, the polymerization initiator may have a content of 40 to300 ppm or 50 to 200 ppm on the basis of the water-solubleethylene-based unsaturated monomers, the polymerization temperature(temperature of the monomer during the polymerization) may be 20 to 45°C., or 25 to 40° C., and the surface cross-linking agent may have acontent of 0.15 to 0.7 wt %, or 0.2 to 0.5 wt % based on the amount ofthe particles.

As described above, when all of the content of the polymerizationinitiator, the polymerization temperature, and the content of thesurface cross-linking agent in the preparation method of the superabsorbent polymer satisfy the above-described ranges, respectively, theweight average molecular weight and the content of the water-solublecomponent included in the super absorbent polymer to be obtained maysatisfy the above-described ranges.

In addition, the polymerization initiator may be at least one selectedfrom the group consisting of a thermal polymerization initiator, a redoxinitiator, and a photopolymerization initiator.

In the preparation method according to the exemplary embodiment of thepresent invention, the polymerization initiator is used. According tothe polymerization method, the photopolymerization initiator may be usedin the photopolymerization method, and the thermal polymerizationinitiator may be used in the thermal polymerization method. Meanwhile,in the photopolymerization method, the thermal polymerization initiatormay be additionally included since a predetermined amount of heat occursby ultraviolet irradiation, and the like, and in addition, as thepolymerization reaction which is an exothermic reaction is performed,some degree of heat occurs.

Specific examples of the thermal polymerization initiator may include atleast one selected from the group consisting of a persulfate-basedinitiator, an azo-based initiator, hydrogen peroxide, and an ascorbicacid. Specifically, examples of the persulfate-based initiator mayinclude sodium persulfate (Na₂S₂O₈), potassium persulfate (K₂S₂O₈),ammonium persulfate ((NH₄)₂S₂O₈), and the like, and examples of theazo-based initiator may include2,2-azobis(2-amidinopropane)dihydrochloride, 2,2-azobis-(N,N-dimethylene)isobutyramidine dihydrochloride,2-(carbamoylazo)isobutylonitril,2,2-azobis[2-(2-imidazolin-2-yl)propane]dihydrochloride,4,4-azobis-(4-cyanovaleric acid), and the like. More various thermalinitiators are specified in “Principle of Polymerization (Wiley, 1981)”,page 203, written by Odian. However, the present invention is notlimited to the above-described examples.

Meanwhile, examples of the photopolymerization initiator may include atleast one selected from the group consisting of benzoin ether, dialkylacetophenone, hydroxyl alkylketone, phenyl glyoxylate, benzyl dimethylketal, acyl phosphine, and α-aminoketone. Meanwhile, specific examplesof acyl phosphine may include commercially available lucirin TPO, thatis, 2,4,6-trimethyl-benzoyl-trimethyl phosphine oxide. More variousphotopolymerization initiators are specified in “UV Coatings: Basics,Recent Developments and New Application (Elsevier, 2007)”, page 115,written by Reinhold Schwalm. However, the present invention is notlimited to the above-described examples.

In addition, the water-soluble ethylene-based unsaturated monomers maybe at least one selected from the group consisting of acrylic acid (alsosalts thereof), acrylate, and methacrylic acid (also salts thereof)including unsaturated hydrocarbons. The water-soluble ethylene-basedunsaturated monomers may have un-neutralized acidic groups.

Further, the water-soluble ethylene-based unsaturated monomers may beused without a limitation in view of a configuration as long as it is amonomer generally used in preparation of the super absorbent polymer.The water-soluble ethylene-based unsaturated monomers may largelyinclude at least any one selected from the group consisting of anionicmonomers and their salts, nonionic hydrophilic-containing monomers, orunsaturated monomers containing amino groups and their quarternarycompounds.

More specifically, the water-soluble ethylene-based unsaturated monomerspreferably include at least any one selected from the group consistingof anionic monomers (e.g., acrylic acid, methacrylic acid, anhydrousmaleic acid, fumaric acid, crotonic acid, itacronic acid, 2-acryloylethane sulfonic acid, 2-methacryloyl ethane sulfonic acid,2-(meta)acryloyl propane sulfonic acid, or 2-(meta)acrylamide-2-methylpropane sulfonic acid) and their salts; nonionic hydrophilic-containingmonomers (e.g., (meta)acrylamide, N-substituted(meta)acrylate,2-hydroxyethyl(meta)acrylate, 2-hydroxypropyl(meta)acrylate,methoxypolyethylene glycol(meta)acrylate, or polyethyleneglycol(meta)acrylate); and unsaturated monomers containing amino groups(e.g., (N,N)-dimethylaminoethyl(meta)acrylate, or(N,N)-dimethylaminopropyl(meta)acrylamide) and their quarternarycompounds.

More preferably, the acrylic acid or salts thereof may be used as themonomer. When the acrylic acid or salts thereof are used as the monomer,the super absorbent polymer, particularly, having improvedabsorptiveness may be obtained.

Meanwhile, a concentration of the water-soluble ethylene-basedunsaturated monomers in the monomer composition may be appropriatelyselected in consideration of a polymerization time, a reactioncondition, and the like. Preferably, the concentration of thewater-soluble ethylene-based unsaturated monomers may be 40 to 55 wt %.When the concentration of the water-soluble ethylene-based unsaturatedmonomers is less than 40 wt %, it is not effective in view of economicfeasibility, and when the concentration of the water-solubleethylene-based unsaturated monomers is more than 55 wt %, at the time ofpulverizing the polymerized hydrogel polymer, a pulverization efficiencymay be decreased.

Before polymerizing the monomer composition, a neutralizing agent may beadded to the monomer composition to neutralize at least some of theun-neutralized acidic groups of the water-soluble ethylene-basedunsaturated monomers.

In addition, the monomer composition may be polymerized by solutionpolymerization.

The polymerization method in the preparing of the hydrogel polymer bythermal polymerizing or photopoymerizing the monomer composition is notlimited in view of a configuration as long as it is a generally usedpolymerization method. Specifically, the polymerization method islargely classified into a thermal polymerization and aphotopolymerization according to a polymerization energy source. Thethermal polymerization may be generally performed in a reactor such as akneader having stirring spindles, and the photopolymerization may beperformed in the reactor provided with a movable conveyer belt. However,these polymerization methods are provided as an example, and the presentinvention is not limited to the above-described polymerization methods.

As an example, the hydrogel polymer obtained by thermal polymerizationby supplying hot air in the reactor such as the kneader having stirringspindles as described above or by heating the reactor, or dischargedfrom an outlet of the reactor may have a few centimeters to a fewmillimeters according to the shape of the stirring spindles provided inthe reactor. Specifically, a size of the obtained hydrogel polymer mayvary according to a concentration and an injection rate of the monomercomposition to be injected, and in general, the hydrogel polymer mayhave a weight average particle diameter of 2 to 50 mm.

In addition, when the photopolymerization is performed in the reactorprovided with the movable conveyer belt as described above, thegenerally obtained hydrogel polymer may be a sheet-shaped hydrogelpolymer having a width of the belt. Here, the thickness of the polymersheet may vary according to the concentration and the injection rate ofthe monomer composition to be injected; however, it is preferred tosupply the monomer composition so as to obtain the sheet-shaped polymerhaving a thickness of 0.5 to 5 cm. When supplying the monomercomposition so that the sheet-shaped polymer has an extremely thinthickness, a production efficiency may be low, which is not preferred,and when a thickness of the sheet-shaped polymer is more than 5 cm, thepolymerization reaction may not be uniformly performed throughout anoverall thickness due to the extremely thick thickness.

Meanwhile, the hydrogel polymer right after the polymerization issubjected to a drying process. It is preferred that a drying temperatureof the drying process is 150° C. to 250° C. Meanwhile, “the dryingtemperature” throughout the specification may be defined as atemperature of a thermal media supplied for drying or a temperature of adrying reactor including the thermal media and the polymer in the dryingprocess.

When the drying temperature is less than 150° C., a drying time may beextremely increased, and thus physical properties of the finally formedsuper absorbent polymer may be deteriorated, and when the dryingtemperature is more than 250° C., only a surface of the polymer may beextremely dried, such that fine powder may occur in a pulverizationprocess to be performed later and physical properties of the finallyformed super absorbent polymer may be deteriorated. Preferably, thedrying process may be performed at a temperature of 150° C. to 200° C.,and more preferably, at a temperature of 160° C. to 180° C.

Meanwhile, the drying time is not limited in view of a configuration,for example, may be 20 minutes to 90 minutes in consideration of aprocess efficiency, and the like.

In addition, the drying method of the drying process may also beselected without limitation in view of a configuration as long as it isgenerally used as a drying process of the hydrogel polymer.Specifically, the drying process may be performed by hot air supply,infrared irradiation, microwave irradiation, ultraviolet irradiation, orthe like. The polymer after performing the drying process may have apercentage of water content of 0.1 to 10 wt %.

Then, the dried polymer is pulverized to form particles of the superabsorbent polymer. The super absorbent polymer or particles of the superabsorbent polymer before performing surface cross-linking may bereferred to as a base resin.

Meanwhile, in order to perform surface cross-linking on the particles,the surface cross-linking agent may be added. Here, the surfacecross-linking agent which is usable is not limited in view of aconfiguration as long as it is a compound which is capable of reactingwith functional groups of the particles.

Preferably, in order to improve properties of the super absorbentpolymer to be produced, examples of the surface cross-linking agent mayinclude at least one selected from group consisting of polyvalentalcohol compounds; epoxy compounds; polyamine compounds; halo epoxycompounds; condensation products of halo epoxy compounds; oxazolinecompounds; mono-, di- or poly-oxazolidinone compounds; annular ureacompounds; polyvalent metal salts; and alkylene carbonate compounds.

Specifically, examples of the polyvalent alcohol compound may include atleast one selected from the group consisting of mono-, di-, tri-, tetra-or polyethylene glycol, mono propylene glycol, 1,3-propanediol,dipropylene glycol, 2,3,4-trimethyl-1,3-pentanediol, polypropyleneglycol, glycerol, polyglycerol, 2-butene-1,4-diol, 1,4-butanediol,1,3-butanediol, 1,5-pentanediol, 1,6-hexanediol, and1,2-cyclohexanedimethanol.

In addition, examples of the epoxy compound may include ethylene glycoldiglycidyl ether and glycidol, and examples of the polyamine compoundmay include at least one selected from the group consisting ofethylenediamine, diethylenetriamine, triethylenetetramine,tetraethylenepentamine, pentaethylenehexamine, polyethylene imine, andpolyamidepolyamine.

Further, examples of haloepoxy compound may include epichlorohydrin,epibromohydrin and α-methyl epichlorohydrin. Meanwhile, examples of themono-, di- or poly-oxazolidinone compound may include 2-oxazolidinone,and the like.

In addition, examples of the alkylene carbonate compound may includeethylene carbonate, and the like. The above-described compounds may beused alone, respectively, or may be combined with each other. Meanwhile,in order to increase an efficiency of the surface cross-linking process,it is preferred to include at least one polyvalent alcohol compounds inthe surface cross-linking agent, and more preferably, C2 to C10polyvalent alcohol compounds may be used.

According to the preparation method of the present invention, thesurface cross-linking agent which is added to the particles as describedabove may have a content of 0.15 to 0.7 wt %, preferably, 0.2 to 0.5 wt% on an amount of the pulverized particles. When the surfacecross-linking agent has the above-described ranged content, the weightaverage molecular weight and the content of the water-soluble componentaccording to the present invention may be obtained.

Here, the method of adding the surface cross-linking agent to theparticles is not limited in view of a configuration. There are a methodof putting the surface cross-linking agent and the particles into areaction bath and mixing the agent with the particles, a method ofspraying the surface cross-linking agent onto the particles, and amethod of continuously supplying the polymer and the cross-linking agentinto a continuously operated mixer and mixing the agent with theparticles.

In addition, when adding the surface cross-linking agent, water may beadditionally added. When adding water, the surface cross-linking agentmay be uniformly dispersed in the polymer. Here, the content of water tobe added is preferably 0.5 to 10 parts by weight on the basis of 100parts by weight of the polymer in order to induce uniform dispersion ofthe surface cross-linking agent, to prevent agglomeration phenomenon ofthe particles, and to optimize a depth at which the cross-linking agentis permeated onto a surface.

Meanwhile, according to another exemplary embodiment of the presentinvention, in order to raise a temperature to the reaction temperaturefor the surface cross-liking at a rate of 3° C./min to 15° C./min afteradding the surface cross-linking agent, the temperature of particlesitself is preferably 20° C. to 90° C. at the time of adding the surfacecross-linking agent. In order to have the temperature of the particlesitself as described above, processes to be performed after the dryingprocess to be performed at a relatively high temperature may becontinuously performed, or processing time may be reduced, or when it isdifficult to reduce the processing time, the particles may be separatelyheated.

In addition, according to another exemplary embodiment of the presentinvention, in order to raise a temperature to the reaction temperaturefor the surface cross-liking at a rate of 3° C./min to 15° C./min afteradding the surface cross-linking agent, the surface cross-linking agentitself to be added to the particles may be heated.

Preferably, the temperature of the surface cross-linking agent to beadded is 10° C. to 90° C., and more preferably, 20° C. to 60° C. Whenthe temperature of the surface cross-linking agent is less than 10° C.,an effect of reducing the raising rate of the temperature to thereaction temperature for the surface cross-linking according to theraise in temperature of the surface cross-linking agent may not besufficient, and when the temperature of the surface cross-linking agentis more than 90° C., the surface treatment agent may not be uniformlymixed.

In addition, the means of raising the temperature for the surfacecross-linking reaction are not limited in view of a configuration. Thetemperature may be raised by supplying the thermal media or directlysupplying heat source. Here, examples of the usable thermal media mayinclude temperature-raising fluids such as steam, hot air and hot oil.However, the present invention is not limited to the above-describedexamples. In addition, a temperature of the supplied thermal media maybe appropriately selected in consideration of the means of thermalmedia, the raising rate of the temperature, and target temperature inraising temperature. Meanwhile, examples of heat source to be directlysupplied may include electricity and gas. However, the present inventionis not limited to the above-described examples.

It is preferred to use the thermal media over 100° C. by consideringthat the temperature of the surface cross-linking is 100 to 250° C., andthe thermal media having an appropriate temperature over 100° C. may beselected in consideration of the raising rate of the temperature, volumeof the reactor, and the kinds of the thermal media.

Meanwhile, after the raising of the temperature for the cross-linking isperformed, the cross-linking reaction may be performed for 1 min to 120mins, preferably, 1 min to 60 mins, and most preferably, 10 mins to 50mins.

When the time for the cross-linking reaction is excessively decreased tobe less than 1 min, sufficient cross-linking reaction may not beperformed, and when the time for the cross-linking reaction is more than120 mins, due to excessive surface cross-linking reaction, physicalproperties may be deteriorated by damage of the polymer particles.

Hereinafter, exemplary embodiments of the present invention will bedescribed in detail. However, these examples are only to illustrate thepresent invention and the scope of the present invention is notconstrued to be limited to these examples.

Example 1

A solution (A solution) obtained by mixing 500 g of acrylic acid with 11g of 1% IRGACURE 819 initiator diluted in acrylic acid and mixing thereaction mixture with 38 g of diluted 5% polyethylene glycol diacrylate(PEGDA, molecular weight 400) was injected into a 2 L glass reactorenclosed with a jacket in which thermal media pre-cooled at 25° C. wascirculated, and 800 g of 24% sodium hydroxide solution (B solution) wasslowly added dropwise, then mixed with together.

After confirming that a temperature of the mixed solution was raised tobe over 80° C. by heat of neutralization at the time of mixing twosolutions and waiting that the reaction temperature was cooled to 40°C., when the reaction temperature arrived at 40° C., 54 g of 2% sodiumpersulfate solution diluted with water was injected thereinto.

The solution was poured into a tray (length: 15 cm×width: 15 cm) in aVat shape installed in a square polymerization reactor having a photoirradiation device mounted thereon and an inner part preheated to 80° C.to perform photo irradiation, such that photo initiation was conducted.It was confirmed that after about 25 seconds from the photo irradiation,gel was generated from a surface, and after about 50 seconds, thepolymerization reaction was generated while simultaneously generatingfoams. Then, after additional reaction was performed for 3 minutes, thepolymerized sheet was cut into a size of 3×3 cm and chopped by a meatchopper to prepare crumbs of hydrogel polymers.

The crumbs were dried in an oven in which air flow transition isvertically possible. The crumbs were uniformly dried by allowing hot airat 180° C. flow from bottom to top for 15 minutes and from top to bottomfor 15 minutes so that the dried polymers had a content of 2% or lessafter the drying process.

After drying, the polymers were pulverized by a pulverizer, and weresubjected to classification and screening to a size of 150 to 850 μm toprepare a base resin. The prepared base resin had a centrifuge retentioncapacity of 38.5 g/g, and a content of the water-soluble component of13.2 wt %.

Next, surface cross-linking was performed on the base resin using 3%ethylene glycol diglycidyl ether solution to react at 120° C. for 1hour. Then, after pulverization, the surface treated super absorbentpolymer having a particle size of 150 to 850 μm was obtained usingsieve.

Example 2

A super absorbent polymer of Example 2 was obtained by performing thesame process as Example 1 except for mixing with 55 g of diluted 5%polyethylene glycol diacrylate (PEGDA, molecular weight 400). Here, theprepared base resin had a centrifuge retention capacity of 36.2 g/g, anda content of the water-soluble component of 11.3 wt %.

Example 3

A super absorbent polymer was obtained by performing surfacecross-linking on the base resin obtained by Example 1. The surfacecross-linking was performed by uniformly distributing 6.3 g of across-linking agent on the base resin, the cross-linking agentcontaining 3.3% of 1,3-propanediol in a mixed solution containing waterand methanol (a ratio between water and methanol is a weight ratio of1:1) on the basis of 100 g of the base resin, and stirring for 1 minuteby a high speed mixer to mix together, then, putting the mixture into astirring bath having a heat jacket to react each other at a temperatureof 185° C. for 50 mins After the reaction, the super absorbent polymerwas pulverized to obtain the surface treated super absorbent polymerhaving a particle size of 150 to 850 μm using sieve.

Example 4

A super absorbent polymer was obtained by performing the same process asExample 3 except for adding 0.3 wt % of aluminum sulfate to the surfacecross-linking agent in the surface cross-linking.

Comparative Example 1

A solution (A solution) obtained by mixing 450 g of acrylic acid with 9g of 10% tetraethylene glycol diacrylate (TEGDA) diluted in acrylic acidwas injected into a 2 L glass reactor enclosed with a jacket in whichthermal media pre-cooled at 60° C. was circulated, and 750 g of 25%sodium hydroxide solution (B solution) was slowly added dropwise, thenmixed with together.

After confirming that a temperature of the mixed solution was raised tobe over 80° C. by heat of neutralization at the time of mixing twosolutions and waiting that the reaction temperature was cooled to 80°C., when the reaction temperature arrived at 80° C., 22.5 g of 10%sodium persulfate solution diluted with water was injected thereinto.

It was confirmed that after the sodium persulfate was injected andstirred for several seconds, the polymerization began immediately. Itwas confirmed that at an initial stage, the mixture was clear, butbecame gradually opaque, and when the gel was formed in the reactor, thestirring was stopped and the polymer polymerization including foamgeneration was actively conducted. It was confirmed that a volumeexpansion rate at the foam generation was increased 30 times or morethan the volume of the initially injected monomer solution.

After 3 minutes, the foam was slowly decreased and the hydrogel polymercould be obtained. The polymer was cut into a size of 3×3 cm and choppedby a meat chopper to prepare crumbs of hydrogel polymer.

The crumbs were dried in an oven in which air flow transition isvertically possible. The crumbs were uniformly dried by allowing hot airat 180° C. flow from bottom to top for 15 minutes and from top to bottomfor 15 minutes so that the dried polymers had a content of 2% or lessafter the drying process.

After drying, the polymers were pulverized by a pulverizer, and weresubjected to classification and screening to a size of 150 to 850 μm toprepare a base resin. Here, the prepared base resin had a centrifugeretention capacity of 40.3 g/g, and a content of the water-solublecomponent of 14.5 wt %.

Next, surface cross-linking was performed on the base resin using 3%ethylene glycol diglycidyl ether solution and reacted at 120° C. for 1hour. Then, after pulverization, the surface treated super absorbentpolymer having a particle size of 150 to 850 μm was obtained usingsieve.

Comparative Example 2

A super absorbent polymer was obtained by performing surfacecross-linking on the base resin obtained by Comparative Example 1. Thesurface cross-linking was performed by uniformly distributing 5 g of across-linking agent on the base resin, the cross-linking agentcontaining 4.2% of 1,3-propanediol in a mixed solution containing waterand methanol (a ratio between water and methanol is a weight ratio of1:1.1) on the basis of 100 g of the base resin, and stirring for 1minute by a high speed mixer to mix together, then, putting the mixtureinto a stirring bath having a heat jacket to react each other at atemperature of 185° C. for 50 mins After the reaction, the superabsorbent polymer was pulverized to obtain the surface treated superabsorbent polymer having a particle size of 150 to 850 μm using sieve.

Comparative Example 3

A super absorbent polymer was obtained by performing the same process asComparative Example 2 except for adding 0.3 wt % of aluminum sulfate tothe surface cross-linking agent in the surface cross-linking.

Physical properties of the super absorbent polymers prepared accordingto Examples and Comparative Examples were measured as follows and theresults thereof were shown in Table 1.

Test Example 1 Measurement of Centrifuge Retention Capacity

A centrifuge retention capacity of the super absorbent polymer particlesprepared according to Examples and Comparative Examples was measured bythe EDANA WSP 241.2 method.

The centrifuge retention capacity was measured by putting 0.2 g of thesample classified to 30 to 50 mesh into tea bags, keeping the samplesoaked in 0.9% saline solution for 30 minutes, removing water in acentrifuge set to 250 G for 3 minutes, and measuring weight so as tomeasure an amount of water retained in the super absorbent polymer.

Test Example 2 Measurement of Water-Soluble Component

Water-soluble component of super absorbent polymer particles preparedaccording to Examples and Comparative Examples was measured by the EDANAWSP 270.2 method. 1.0 g of the sample classified to 30 to 50 mesh wereput into 200 g of 0.9% saline solution, and kept to be soaked for 16hours while stirring at 500 rpm, and each aqueous solution was filtratedby a filter paper. Each filtrated solution was primarily titrated withsodium hydroxide solution (pH 10.0), reverse-titrated with a hydrogenchloride solution (pH 2.7), and as the water-soluble component, thepolymer material which was not cross-linked was calculated from theamount required for the neutralization.

Test Example 3 Measurement of Average Molecular Weight of Water-SolubleComponent

Weight average molecular weight of the water-soluble components of thesuper absorbent polymers prepared according to Examples and ComparativeExamples was measured. 1.0 g of the sample classified to 30 to 50 meshwere put into 200 g of 0.9% saline solution, and kept to be soaked for16 hours while stirring at 500 rpm, and the aqueous solution wasfiltrated by a filter paper. Each filtrated solution was separated bygel permeation chromatograph (GPC) column for measurement.

GPC was performed on an instrument manufactured by Wyatt DAWN EOS, WyattOptilab DSP, Waters, or Wyatt using Ultrahydrogel Linear X2 as a column,0.1 M NaNO₃/0.02 M phosphate buffer as a solvent under the conditions ofa flow rate of 0.8 mL/min and a temperature of 60° C., and polyacrylicacid was used as a standard.

Test Example 4 Measurement of Permeability

Lines were marked on liquid level height of 20 ml and 40 ml in a statein which piston was put into a chromatography tube (F20 mm) Then, waterwas injected reversely up to about 10 ml so that foams between a glassfilter and a cock at a low part of the chromatography tube were notgenerated, then the chromatography tube was washed with saline solutiontwo or three times, and filled with 0.9% saline solution up to 40 ml ormore. The piston was put into the chromatography tube and a lower valvewas opened, then, a time (B) required for decreasing the liquid levelheight from 40 ml up to 20 ml was recorded.

The classified sample (30# to 50#) having 0.2±0.0005 g was put into thechromatography tube filled with 10 ml of saline solution, then, salinesolution was added to have a volume of 50 ml, and then left for 30minutes. Then, after a piston (0.3 psi=106.26 g) with a weight was putinto the chromatography tube, the tube was left for 1 minute, then, alower valve of the chromatography tube was opened, and a time (T1)required for decreasing a liquid level height from 40 ml up to 20 ml wasrecorded to calculate a time of T1−B.

TABLE 1 Super Absorbent Polymer Weight Average Centrifuge AbsorbencyWater-Soluble Molecular Weight of retention capacity under loadPermeability Component Water-Soluble (g/g) (g/g) (sec) (%) ComponentExample 1 34.5 24.5 85 13.2 250,000 Example 2 33.5 25.1 97 11.3 220,000Example 3 34.2 23.8 115 9.7 236,000 Example 4 32.7 25.5 52 10.2 187,000Comparative 33.7 24.4 165 14.5 140,000 Example 1 Comparative 32.1 23.6183 12.4 125,000 Example 2 Comparative 31.8 22.7 78 13.6 132,000 Example3

The present invention has been described in detail based on particularfeatures thereof, and it is obvious to those skilled in the art thatthese specific technologies are merely preferable embodiments and thusthe scope of the present invention is not limited to the embodiments.Therefore, the substantial scope of the present invention will bedefined by the accompanying claims and their equivalents.

What is claimed is:
 1. A super absorbent polymer, comprising: surfacecross-linked polymer particles prepared by surface cross-linkingparticles of a base resin, the base resin polymerized from a monomercomposition including water-soluble ethylene-based unsaturated monomershaving at least partially neutralized acidic groups; and a water-solublecomponent, wherein the water-soluble component has a weight averagemolecular weight of 150,000 to 300,000 g/mol.
 2. The super absorbentpolymer of claim 1, wherein the water-soluble component has a content of5 to 20 wt %, based on the total weight of the super absorbent polymer,as measured by the EDANA WSP 270.2 method.
 3. The super absorbentpolymer of claim 1, wherein a centrifuge retention capacity is 20 to 35g/g as measured by the EDANA WSP 241.2 method.
 4. The super absorbentpolymer of claim 1, wherein an absorbency under load is 20 to 30 g/g asmeasured by the EDANA WSP 242.2 method.
 5. The super absorbent polymerof claim 1, wherein a permeability of the super absorbent polymermeasured according to the following Equation 1 is 10 to 150 seconds:Permeability (sec)=T1−B  [Equation 1] T1 represents a time required fordecreasing a liquid level height from 40 ml up to 20 ml under a load of0.3 psi (106.26 g) in a chromatography tube in the presence of salinesolution-absorbed super absorbent polymer, wherein the salinesolution-absorbed super absorbed polymer is prepared by putting0.2±0.0005 g of a classified sample (30# to 50#) (particles size rangingfrom 300 μm to 600 μm) of super absorbent polymer into thechromatography tube and adding saline solution so that the salinesolution has a volume of 50 ml, and leaving the tube for 30 minutesprior to measuring T1, and B represents a time required for decreasing aliquid level height from 40 ml up to 20 ml in a chromatography tubefilled with saline solution under a load of 0.3 psi in the absence ofthe super absorbent polymer.
 6. A preparation method of a superabsorbent polymer, comprising: preparing a monomer composition includinga water-soluble ethylene-based unsaturated monomers have un-neutralizedacidic groups, and a polymerization initiator, wherein thepolymerization initiator has a content of 40 to 300 ppm based on theamount of water-soluble ethylene-based unsaturated monomers; adding aneutralizing agent to the monomer composition to neutralize at leastsome of the un-neutralized acidic groups of the water-solubleethylene-based unsaturated monomers; preparing a hydrogel polymer bypolymerizing the monomer composition, wherein a polymerizationtemperature ranges from 20 to 45° C.; drying the hydrogel polymer;pulverizing the dried polymer to form particles; and surfacecross-linking the particles in the presence of a surface cross-linkingagent to form surface cross-linked polymer particles of the superabsorbent polymer, wherein the surface cross-linking agent is present inan amount ranging from 0.15 to 0.7 wt % based on an amount of theparticles.
 7. The preparation method of claim 6, wherein the superabsorbent polymer includes a water-soluble component included in thesuper absorbent polymer has a weight average molecular weight of 150,000to 300,000.
 8. The preparation method of claim 6, wherein the surfacecrosslinking is performed at temperatures ranging from about 120 toabout 185 degrees Celsius.
 9. The preparation method of claim 6, whereinpreparing the monomer composition further comprises: adding an internalcross linking agent.
 10. The preparation method of claim 6, wherein thesurface cross-linking agent includes aluminum sulfate.
 11. A hygieneproduct including the super absorbent polymer of claim
 1. 12. Adisposable diaper including the super absorbent polymer of claim 1.